Atraumatic medical retrieval device

ABSTRACT

Baskets with atraumatic distal tips allow the capture of material from difficult-to-reach areas of the body, while reducing the risk of tissue damage.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is based on and claims priority to provisional U.S.patent application Ser. No. 60/082,810 which was filed on Apr. 23, 1998,and U.S. provisional patent application Ser. No. 60/105,448 which wasfiled on Oct. 23, 1998.

TECHNICAL FIELD

The invention relates generally to medical devices for retrievingmaterial from within a body. More particularly, the invention relates tomedical retrieval baskets that have atraumatic distal ends that arecontoured or tipless both to minimize the chances of damage to tissueduring use and to enhance the ability of the basket to capture material(e.g., stones) disposed or lodged in “pockets” or other areas that aredifficult to access in the body.

BACKGROUND INFORMATION

Known stone retrieval devices typically have baskets that areconstructed by joining multiple legs together at a base of the basketand at a distal end or tip of the basket such that a “cage” is formed.At the distal tip, the individual legs are joined by soldering,adhesives, etc. such that a protruding tip results. This protrusion oroutward projection at the distal end of the basket can poke tissue andcause tissue trauma. In general, the tips or ends of known basketsprotrude outward and thus can cause damage by poking or piercing tissue.Also, the protruding tips of known baskets generally do not permitaccess to or intimate contact with certain areas within the body such as“pockets,” and thus stones residing in such areas are difficult orimpossible to retrieve with known baskets.

SUMMARY OF THE INVENTION

It is an object of the invention to provide a medical retrieval basketthat does not have a substantially protruding distal basket end orbasket tip. That is, a basket according to the invention is atraumaticand does not have any significant distal protrusion or outwardprojection that can poke tissue, pierce tissue, or otherwise causetrauma to tissue.

It is another object of the invention to provide a medical retrievalbasket that permits access to and/or intimate contact with certain areaswithin the body such as “pockets” where material to be retrieved (e.g.,stones) might reside or be lodged, impacted, or embedded. A tipless orcontoured tip basket arrangement can access these areas and retrievematerial from those areas whereas a conventional basket with a traumatictip would not be able to do so because of the traumatic protruding tipthat prevents intimate contact between the distal end of the basket andbody tissue.

It is yet another object of the invention to provide a method of usingsuch baskets to retrieve material from within a body. The material canbe biological or foreign matter. The material can be, for example,urological stones or any of a variety of other types of material foundin the body.

A basket according to one aspect of the invention is tipless and thuslacks a protruding end or tip. At least a distal end portion of thebasket can be formed from a single piece of material to achieve thedesired tipless feature. The one-piece construction of at least thedistal end portion of the tipless basket can be achieved by removing thedesired profile from a flat sheet of construction material or by usingan injection mold process. With this type of single unit, one-piececonstruction, the basket legs require joining only at the base of thebasket where the basket is attached to a cable, coil, wire, etc., thatconnects the basket to a proximal handle mechanism. This single unitfeature of baskets according to the invention can be achieved in avariety of ways including stamping, photoetching, laser cutting, andinjection molding. Also, various materials can be used to form thetipless one-piece unit or the entire basket such as metal, polymers,ceramics, powdered metals, thermal plastic composites, etc. Combinationsof these or other materials also may be used to manufacture a basketaccording to the invention.

The invention generally relates to a medical retrieval device thatcomprises a sheath, a handle, and an atraumatic basket. The sheath has aproximal end and a distal end. The handle is located at the proximal endof the sheath. The basket can remove material from a body, and it has acollapsed position where the basket is enclosed within the sheath and anexpanded position where the basket extends from the distal end of thesheath. The basket can have three or more legs (e.g., four, five, or sixlegs). At least a distal end portion of the basket is substantiallytipless and defined by a shape or profile which comprises a singlecontinuous unit. In another embodiment of the invention, the atraumaticbasket is formed by a plurality of wires, each wire forming a loop witha small protrusion at the very distal end of the basket.

In accordance with one aspect of the invention, the atraumatic baskethas a distal end portion defined by a single continuous, one-piece unit.The atraumatic basket can include the following features. The distal endportion of the atraumatic basket can be non-perforated or perforated to,for example, allow a guidewire or lithotripsy device (laser) to extendthrough the sheath and through the end of the basket. The shape of thedistal end portion of the atraumatic basket can be formed from, forexample, metal, metal alloys, a ceramic material, a powdered metal, or apolymer. The basket legs, each of which has an inner surface and anouter surface, can have at least a portion of their inner surfacescoated with an anti-slip material, textured, or roughened in some mannerto enhance the ability of the basket to grip and hold material. Theatraumatic basket can be made by one-piece construction forming, as asingle continuous one-piece unit, a shape having three or more legs, forexample, a y-shape, x-shape, t-shape or star-shape, and then bending thelegs of the shape to form at least a distal portion of athree-dimensional basket structure that is useful for retrievingobjects. Other shapes such as a double loop may be used to form thedistal portion of the basket. Shapes other than the ones described herealso may be used to form the distal portion of the basket. The shape canbe stamped, etched, and/or cut from a continuous sheet of material.Alternatively, the shape could be achieved by injection molding.

In another embodiment of an atraumatic wire basket, the distal ends ofthe basket wires insert into an inverted cap at the distal basket tip.

Another aspect of the invention relates to a method for manufacturing abasket for a medical retrieval device comprising the steps of forming,as a single continuous unit, a shape having three or more legs andbending the legs of the shape to form at least a portion of athree-dimensional basket structure for retrieving objects. The shape canbe stamped, etched or cut from a continuous sheet of material. The shapecan also be injection molded.

Yet another aspect of the invention features a method for retrievingmaterial from a body including the steps of inserting an extractor intoa body, the extractor including a basket having three or more legs andwherein at least a distal end portion of the basket is defined by ashape which comprises a single continuous unit, capturing the materialwithin the basket and withdrawing the extractor from the body to removethe material from the body.

The foregoing and other objects, aspects, features, and advantages ofthe invention will become more apparent from the following descriptionand from the claims.

BRIEF DESCRIPTION OF THE DRAWINGS

In the drawings, like reference characters generally refer to the sameparts throughout the different views. Also, the drawings are notnecessarily to scale, emphasis instead generally being placed uponillustrating the principles of the invention.

FIG. 1A illustrates a top view of an X-profile embodiment of a one-piececonstruction of at least a distal end portion of a medical retrievalbasket removed from a single piece of substantially flat materialaccording to the invention.

FIG. 1B illustrates a side view of an embodiment according to theinvention of a three-dimensional atraumatic tipless basket formed bybending and shaping the legs of the X-profile illustrated in FIG. 1A.

FIG. 1C illustrates a side view of an embodiment according to theinvention of the X-profile illustrated in FIG. 1A.

FIG. 1D illustrates an embodiment according to the invention of an endview of the X-profile illustrated in FIG. 1A.

FIG. 1E illustrates one embodiment of a medical retrieval device with anatraumatic basket according to the invention with the basket in anexpanded position.

FIG. 1F illustrates one embodiment of a medical retrieval device with anatraumatic basket according to the invention with the basket in acollapsed position.

FIG. 1G illustrates a side view of one embodiment of the invention of adistal end portion of a basket formed by bending and shaping the legs ofthe X-profile illustrated in FIG. 1A.

FIG. 1H illustrates an embodiment of the medical retrieval deviceaccording to the invention with a lithotriptic device extending into thebasket lumen;

FIG. 2A illustrates a top view of one embodiment of an X-profile,one-piece construction of a distal end portion of the basket of theinvention.

FIG. 2B illustrates details of the center of the X-profile illustratedin FIG. 2A.

FIG. 2C illustrates details of the end of one leg of the X-profileillustrated in FIG. 2A.

FIG. 2D illustrates embodiments of a cross-section of one of the legsillustrated in FIG. 2A.

FIG. 2E illustrates another embodiment of a cross-section of one of thelegs illustrated in FIG. 2A.

FIG. 2F illustrates one embodiment of a modification of the end of abasket leg;

FIG. 3A illustrates a top view of a parachute-shaped profile embodimentof a one-piece construction of a medical retrieval basket removed from asingle piece of substantially flat material according to the invention.

FIG. 3B illustrates a side view of an embodiment according to theinvention of a three-dimensional atraumatic tipless basket formed bybending and shaping the profile of the parachute shape illustrated inFIG. 3A.

FIG. 3C illustrates the basket of FIG. 3B enclosed within a sheath.

FIG. 3D illustrates the basket of FIG. 3B extended from the distal endof the sheath.

FIG. 4A illustrates a top view of a web-shaped profile embodiment of aone-piece construction of at least a distal end portion of a medicalretrieval basket removed from a single piece of substantially flatmaterial according to the invention.

FIG. 4B illustrates a side view of an embodiment according to theinvention of a three-dimensional atraumatic basket formed by bending andshaping the profile of the web-shaped profile illustrated in FIG. 4A.

FIG. 5A illustrates a top view of a double loop-shaped profileembodiment of a one-piece construction of at least a distal end portionof a medical retrieval basket removed from a single piece ofsubstantially flat material according to the invention.

FIG. 5B illustrates a side view of an embodiment according to theinvention of a three-dimensional atraumatic tipless basket formed bybending and shaping the profile of the double-loop shaped profileillustrated in FIG. 5A.

FIG. 6A is a top view of a stamped profile that can be formed into abasket or a portion of a basket by bending the legs of the shape, inaccordance with the invention.

FIG. 6B is an embodiment according to the invention of athree-dimensional tipless basket with a distal end portion constructedfrom the profile illustrated in FIG. 6A.

FIG. 7A is an embodiment according to the invention of athree-dimensional tipless basket structure formed from a singlecontinuous piece of material, for example, the stamped shape illustratedin FIG. 6A.

FIG. 7B is the distal end profile illustrated in FIG. 6A including atextured inner surface of one leg.

FIG. 8 is a top view of an embodiment according to the invention ofanother stamped shape that can be formed into a basket or a portion of abasket by bending the legs of the shape, according to the invention.

FIG. 9 illustrates an embodiment according to the invention of a basketwith an atraumatic spot-welded tip.

FIG. 10 illustrates an embodiment according to the invention of a basketwith an atraumatic looped tip.

FIG. 11A illustrates a loop of a basket according to the invention.

FIG. 11B illustrates an embodiment of a three-dimensional basketaccording to the invention formed from a plurality of basket loopsillustrated in FIG. 11A.

FIG. 11C illustrates a loop of a basket according to the inventionhaving an atraumatic protrusion with a radius at the distal end.

FIG. 11D illustrates an embodiment of a three-dimensional basketaccording to the invention formed from a plurality of basket loopsillustrated in FIG. 11C.

FIG. 12A illustrates another embodiment of the basket loop havingmultiple shoulders illustrated in FIG. 11C.

FIG. 12B illustrates yet another embodiment of the basket loopillustrated in FIG. 12A.

FIG. 12C illustrates an embodiment of a three-dimensional basket formedfrom basket loops having multiple shoulders illustrated in 12A.

FIG. 12D illustrates an embodiment of a three-dimensional basket formedfrom basket loops illustrated in FIG. 12B.

FIG. 13A illustrates an inverted cap embodiment of a tipless basket.

FIG. 13B illustrates the distal end portion of the inverted cap, tiplessbasket illustrated in FIG. 13A before the ends of the basket legs areaffixed together at the proximal end of the basket.

FIG. 13C illustrates the details of the inverted cap illustrated inFIGS. 13A and 13B.

FIG. 14 illustrates a metal ring inserted into a polyimide sheath beforethe metal ring is ground flush with the end of the polyimide sheath.

DESCRIPTION

All of the following embodiments of the invention generally have atleast one thing in common, a basket of a medical retrieval device havinga substantially atraumatic tip according to the invention. The basket10, shown by way of example in FIG. 1F, is the type that can becollapsed within a sheath 12 for entry into the body. A medical deviceor extractor that includes the basket 10 of the invention also includesthe sheath 12 and a proximal handle 8. The handle 8, sheath 12, andbasket 10 illustrated in FIGS. 1E and 1F are not shown in their correctsize or proportion to each other. The size of the entire sheath isdimensioned to fit the requirements of its application in the body. Forexample, for urological applications, the size of the device istypically 1.7-8.0 Fr. The sheath 12 has at least one lumen 14 therein,may be made from a single material, and extends from the handle 8 to adistal sheath end 16. An elongated member such as a cable, coil, shaft,guidewire or mandril wire 18 extends within the lumen 14 from anactuating mechanism 4 at the device handle 8 to the base 20 of thebasket 10, where the cable 18 is attached to the basket base 20.Operation of the actuating mechanism 4 by an operator causes the basket10 to move in and out of the sheath 12 between a collapsed positionwithin the sheath 12 as illustrated in FIG. 1F to an extended positionoutside of the sheath 12 where the basket 10 is open/expanded andextending beyond the distal end of the sheath 16 as shown in FIG. 1E.Alternatively, the mechanism 4 can cause movement of the sheath 12 toadvance the sheath 12 over the stationary basket 10 and cable 18combination, to thereby collapse the basket 10 within the sheath 12, andthe mechanism 4 can slide the moveable sheath 12 back to expose thestationary basket 10 and allow it to open/expand. In general, both typesof basket/sheath movement configurations and related handle mechanismsare known, and can be seen in existing product designs available from,for example, Boston Scientific Corporation (Natick, Mass.). With thebasket collapsed within the sheath 12 as shown in FIG. 1F, the sheath 12can be inserted into the body by an operator to a site in the body wherethe material to be retrieved is located (e.g., a stone in the ureter).By putting the basket 10 into its open/expanded position, as illustratedin FIG. 1E, the basket 10 dilates the body tract in which it has beenplaced and can be manipulated by the operator to entrap or capturematerial within the basket 10. The basket 10 and/or the sheath 12 canthen be moved to cause the legs 11 a, 11 b, 11 c, 11 d of the basket 10to close around the material and capture it. The captured material isthen withdrawn from the body along with the sheath and the basket thatis holding the material.

In one aspect, according to the invention, a basket 10 of a device forretrieving biological or foreign material from a body has a plurality oflegs, for example, as shown in FIG. 1B, four legs 11 a, 11 b, 11 c, 11d. An end-on view of the basket 10 in FIG. 1D illustrates asubstantially tipless or atraumatic distal end 100. A small,insubstantial protrusion or depression may remain at the distal tip as aresult of the manufacturing process. Such features on the basket tip donot poke, tear, pierce, perforate, bruise or otherwise inflict injury orcause trauma to the tissue and may enhance basket performance. In oneembodiment, for example, the legs 11 a, 11 b, 11 c, 11 d and theatraumatic basket 10 can be cut, etched, stamped or otherwise removed asa single shape or profile from a substantially flat piece of material101 as illustrated in FIG. 1A. In another embodiment, referring to FIGS.1E, 1G and 6B, just the distal end portion 5 of the basket 10 is removedas a single shape or profile from a single piece of substantially flatmaterial. Alternatively, the basket 10 or distal end portion 5 can beinjection molded into the desired shape by, for example, plasticinjection molding, metal-injection-molding (MIM) or by compression ofmetal powders. As illustrated in FIG. 1A and FIG. 1C, the startingprofile for the basket 10 or the basket end portion 5 can be anX-profile or X-shape. After removal of the X-profile from the flatmaterial, the three-dimensional basket 10 or distal end portion 5 of thebasket 10 can be formed by bending and shaping the legs of an X-profile.The starting profile may be asymmetrical. For example, in otherembodiments, the starting profile of the basket 10 or the distal endportion 5 can be y-shaped, t-shaped or star-shaped.

With continued reference to FIGS. 1B and 1D, the distal end 100 of thebasket 10 is uniform, contoured, and substantially without anyprotruding surface features. That is, in accordance with the invention,the distal end 100 of the basket 10 is substantially devoid of knobs,protrusions, fasteners, or outward projections. The distal end 100 ofthe basket 10 may be perforated 20 as illustrated in FIG. 1G to permit aguidewire (not shown) to extend through the sheath 12 and out the end ofthe basket 10 through the perforation 20. Referring to FIG. 1H,alternatively, a ram-rod, laser or other lithotriptic device 9 islongitudinally disposed in a channel 200 of sheath 12. Channel 200extends through the proximal end 20 of the basket 10. In operation, astone 50 is captured in the lumen of the basket 10. The lithotripticdevice is advanced beyond the proximal basket end into the basket untilthe lithotriptic device approaches the stone 50. The stone 50 is thenfragmented by lithotripsy. The fragmented stones are removed from thebody while entrapped within the basket 10.

No adhesive or any other attachment material or device is used at thedistal end 100 of the basket 10 to hold the legs together as at leastthe distal ends of the legs are formed by a profile including distal legportions extracted from a single piece of sheet-like material asillustrated in FIGS. 1A and 1C to form a tipless atraumaticthree-dimensional basket as illustrated in FIG. 1B. The distal end 100of the basket 10 is substantially atraumatic in that it has nosubstantial outward projections or protrusions that might cause injuryor trauma to tissue and/or that might present an impediment tocontacting the distal end 100 of the basket 10 directly and intimatelywith tissue.

In one embodiment, referring to FIGS. 2A-2E, a medical device of theinvention includes a plurality of legs forming the basket 10. The legscan have various cross-sectional shapes, for example, as shown in FIGS.2D and 2E. Other cross-sectional shapes for the legs of the basket 10include, but are not limited to, a D-shape, a V-shape, a B-shape,rectangular, and cylindrical (not shown). Typically, the length of thelegs 11 a, 11 b, 11 c, 11 d is about 0.5 to 3.5 inches, for example, 1.1to 1.5 inches, the width of the leg is about 0.005 inches to 0.015inches and the thickness of the legs is 0.028 inches to 0.045 inches.The ends 1 of the basket legs 11 may be modified by narrowing, enlargingor grooving the end for example, as shown in FIG. 2F, to ease assemblyand/or strengthen the basket when the ends of the basket legs arebrought together.

Referring to FIGS. 2A-2C and 2E, a typical basket end portion may havethe following features. The basket end portion can have four legs, thelegs being approximately 90° apart. The leg length d₁ is 1.1 inches to1.25 inches, leg width d₂ is 0.010 inches to 0.012 inches, leg width d₃is 0.006 inches to 0.008 inches, and leg thickness d₄ is 0.005±0.0003 to0.0032±0.003 inches. At the intersection 121 of the four legs, the fourcorners have a slight radius as shown in FIG. 2B. The ends 1 of the legsas illustrated in FIG. 2C have a full radius. Notches or cut-outs 123are located 0.100 inches (d₆) from the end 1 of the leg and have aradius of 0.003-0.004 inches with a minimum distance (d₅) of 0.004inches between the apex of the notches. The “X” profile illustrated inFIG. 2A may be removed from a flat annealed, superelastic,nickel-titanium sheet having a pickled surface and active A_(f) of 15±5°C.

The basket 10 or distal end 100 of the basket 10 can be formed fromvarious materials such as stainless steel, metal alloys, superelasticmaterials, shape memory materials, powdered metals, ceramics, thermalplastic composites, ceramic composites, polymers, etc. Also,combinations of these and other materials can be used.

The atraumatic basket 10 can assume shapes more complex than one withthree or more legs running parallel and longitudinally from the distalend of the basket to the basket base. For example, referring to FIG. 3A,a single-unit hourglass profile 22 can be removed from a single piece ofsheet-like material 101 by stamping, etching, or cutting, for example,according to the invention. A three-dimensional basket 10 can be createdby folding the single-unit hourglass profile, as illustrated by thearrows in FIG. 3A, into a substantially parachute-shaped configurationas shown in FIG. 3B. Heat treatment, cold-forming, or other shapingprocesses using a ball-shaped die is then performed on theparachute-shaped configuration to shape the profile into athree-dimensional basket 10. The distal end 100 of this basket 10 istipless and atraumatic. The proximal end 24 of basket 10 can be joinedto a cable 18 within a sheath 12 as illustrated in FIG. 3C. The basket10 is moveable relative to the sheath 12 from a collapsed basketposition, shown in FIG. 3C to an open basket position shown in FIG. 3D.

In another embodiment, the basket can be made by extracting a singleunit web-shaped profile 26, as illustrated in FIG. 4A, from a singlepiece of sheet-like material. The web-profile is removed from a singlepiece of sheet-like material by stamping, etching or cutting, forexample. The web-profile is subsequently shaped and molded around a ballshape by heat treatment, cold-forming, or other shaping processes toachieve a basket 10 as illustrated in FIG. 4B. The distal end 100 ofthis basket 10 is atraumatic and substantially tipless. The proximal end24 of basket 10 can be joined to a cable (not shown) and the basket canbe moved within the lumen of a sheath relative to the sheath in a mannersimilar to the basket illustrated in FIGS. 3C and 3D.

Referring to FIG. 5, another embodiment of the basket can be made byextracting a single unit double-loop profile 28 from a single piece ofmaterial by stamping, etching, or cutting, for example. The double-loopprofile 28 is shaped and molded around a ball shape by heat treatment,cold-formed, or by other shaping processes, to form the basket 10illustrated in FIG. 5B. The distal end 100 of the basket 10 issubstantially tipless and atraumatic. The proximal end 24 of the basketcan be joined to a cable (not shown) and the basket can be moved withinthe lumen of a sheath, relative to the sheath in a manner similar to thebasket illustrated in FIGS. 3C and 3D.

To manufacture a basket according to the invention, a single piece offlat material, such as a sheet of metal, or a single piece of materialcontoured to conform to the basket radius is used to form the distalbasket tip. When starting with a single piece of flat material, at leastthe distal basket tip is defined by a shape or profile that is removedfrom the single piece of construction material. The profile can beremoved from the material by a variety of methods including, forexample, stamping, etching, photoetching, or laser cutting asillustrated in FIGS. 1A or 3A. The profile removed from the single pieceof material is then shaped by heat treatment, cold-forming process or byother processes known in the art to form at least a distal end portion 5as illustrated, for example, in FIGS. 1G and 6B having an atraumaticdistal tip, or a three-dimensional basket structure, for example, asillustrated in FIGS. 1B, 3B, 4B and 5B having an atraumatic distal tip.Alternatively, the basket legs may be rotated or twisted slightly aroundtheir longitudinal axis to achieve a helical basket, for example, asshown in FIG. 1D.

A basket according to the invention also can be formed by injectionmolding the distal basket portion or desired basket profile.Alternatively, with a metal or plastic injection molding process, thethree-dimensional distal basket portion or basket design can be injectedinto a three-dimensional mold thereby obviating the step of shaping thedistal basket portion or basket structure following removal of theprofile from a single piece of construction material by molding into afinal shape.

The basket 10 and basket designs described below are joined at thebasket proximal end to the distal end of the elongated member 18 to forma subassembly. The basket/elongated member subassembly is inserted intothe sheath 12 and joined to the handle 8 to form the medical retrievaldevice according to the invention.

The “X” profile that is shown in FIG. 6A, for example, can be replacedby any other shape that lends itself to clinical efficiency andmanufacturability and that results in a substantially tipless atraumaticbasket. The “X” or other profiles can have a small, atraumaticprotrusion or depression at the distal basket tip. Also, the “X” profileor other profile, can be shaped to make a distal end portion 5 of thebasket 10, and leg extensions 3 a, 3 b, 3 c, 3 d can be added toend-sections 1 a, 1 b, 1 c, 1 d of legs 11 a, 11 b, 11 c, 11 d to formall of or a portion of the basket legs 11 a, 11 b, 11 c, 11 d as shownin FIG. 6B. Alternatively, the end-sections 1 a, 1 b, 1 c, 1 d of thebasket legs 11 a, 11 b, 11 c, 11 d of the “X” profile or any otherprofile can be secured together at the base 20 of the basket 10illustrated in FIG. 7A.

All or a portion of the inner surface (side toward basket center) of oneor more of the basket legs can be treated to enhance the ability of thebasket to grasp and hold material to be retrieved. For example, ananti-slip coating, such as a rubberized or plastic coating can beapplied to at least a portion of the inner surface of at least one ofthe basket legs as illustrated on the inner surface 15 of leg 11 b inFIG. 7A. The coating can be applied directly to the single piece ofsheet-like material from which the basket profile is extracted beforebasket formation or to the inner surface of the basket legs after basketformation. An enhanced grasping and/or fragmentation capability also canbe achieved by adding texture to at least the inner surface of at leastone of the basket legs by, for example, creating serrations, teeth, orpoints on the inner surface(s). This can be achieved by, for example,etching, pitting, bending, stamping or machining the texture/roughnessinto the inner surface(s) by application of these methods directly tothe single piece of sheet-like material from which the basket or basketdistal end shape is extracted before basket formation, or directly tothe inner surface of the basket legs after basket formation.

Referring to FIGS. 6A, 7B, and 8, according to one embodiment of theinvention, a profile stamped from a single piece of sheet-like materialhas end-sections 1 that are brought together at a basket base 20 to forma three-dimensional basket 10. Alternatively, as illustrated in FIGS. 6Aand 6B, just the distal end portion 5 of the basket can be formed fromthe single piece of construction material with the legs of the basketextending from the end-sections 1 a, 1 b, 1 c, 1 d of the profile andthen drawing the end-sections 1 a, 1 b, 1 c, 1 d down and bringing theend-sections together at the basket base 20 to form the basket 10. Asshown in FIG. 8, it is possible to have more than three or four basketlegs by forming the basket distal end from, for example, an eight-leg 11a, 11 b, 11 c, 11 d, 11 e, 11 f, 11 g, 11 h star-shape profile 28extracted as a single unit from a single piece of sheet-like material.The shape forming the distal end portion of the basket may beasymmetrical.

Baskets that are atraumatic and tipless may also have each leg 11 a, 11b, 11 c, 11 d joined at the distal end 100 of the basket in a variety ofways such as by spot welding the legs at the distal end 100 asillustrated in FIG. 9 or by looping two or more wires 17 a, 17 btogether at the distal end 100 as illustrated in FIG. 10. The wires arelooped together by forming a loop in a mid-portion of the first wire 17a. Second wire 17 b is passed through the loop of the first wire 17 a.The second wire 17 b is looped within and is held by the loop of thefirst wire 17 a.

Referring to FIGS. 11A and 11B, in another embodiment of the invention,a tipless end 130 of the atraumatic basket 10 is constructed by usingsingle wires to form loops 120 a, 120 b having legs 11 a, 11 b, 11 c, 11d extending from the apex 130 a, 130 b of the loops 120 a and 120 b,respectively, the apex 130 a, 130 b positioned at the basket distal end100. A plurality of pre-formed wire loops is included in athree-dimensional, atraumatic basket. Wire loops may be formed fromplastics, superelastic materials, stainless steel, shape memory metals,ceramic composites, other composites, or other materials and may haveany of a variety of cross sectional shapes such as D-shape, B-shape,U-shape, round, half-round, oval, rectangular or ribbon-like. In thisembodiment of an atraumatic wire basket, two wire loops 120 a, 120 b,for example, may be used to form a basket with four legs 11 a, 11 b, 11c, 11 d as shown in FIG. 11A, and three wire loops 120 a, 120 b, 120 cmay be used to form a basket with six legs 11 a, 11 b, 11 c, 11 d, 11 e,11 f as shown in FIG. 11B. Additional wire loops may be used to form abasket with more than the four or six legs shown. The apex 130 of eachwire loop 120 intersects the apex 130 of the other wire loops 120 of thebasket 10 at the basket distal end 100. The wire loops 120 at the basketdistal end 100 are free to slide by one another, i.e., they are notaffixed, fused, soldered, welded, glued, joined, secured or attached toone another. The advantages of this configuration of the basket is thatthe basket end 100 is atraumatic and provides flexibility therebyenhancing the ease by which stones are captured. The two end-sections 1,1′ of each wire loop are brought together at the basket base 20 and heldin place by welding, soldering, ligating, gluing, crimping or any othermeans known in the art. In one embodiment, the end-sections 1, 1′ of thewire loops are affixed (not shown) to a cable, coil, shaft, mandril wireor guidewire 18 that runs longitudinally in a sheath 12 as shown in FIG.1E and FIG. 1F.

Referring to FIGS. 11C and 11D, the tipless end 100 of the atraumaticbasket can also be constructed by using single pre-formed wires to formmodified loops 120, each modified loop having a pair of legs 11 a, 11 bextending from the apex 130 of the loop 120, the apex 130 positioned atthe basket distal end 100. The apex 130 of a pre-formed wire loop 120forming pairs of basket legs is modified to stabilize the basket tip.For example, as illustrated in FIG. 11C, the apex 130 of a wire loop 120is modified by a protrusion 140 with a radius, such as a semi-circularprotrusion. A basket may be formed by a plurality of wire loops 120 a,120 b, each wire loop having a small protrusion 140 a, 140 b with aradius, as illustrated in FIG. 11D. Each semi-circular protrusion on thebasket wire has a convex surface 142 and a concave surface 144 asillustrated in FIG. 11C. In this embodiment, the convex surface 142 ofthe semi-circular protrusion 140 of wire loop 120 a meets the concavesurface 144 of the semi-circular protrusion 140 of the outer wire loop120 b where the wires of the basket cross one another at the basketdistal tip 100 as illustrated in FIG. 11D. At the apex 130 where theloops cross one another at the distal end of the basket, the wiresforming the loops are not adhered, affixed, fused, soldered, welded,glued or joined to one another. Typically, two or more wires (i.e.,loops), each with a semi-circular protrusion, are used to form anatraumatic wire basket.

Wire loops 120 may be formed from superelastic materials, stainlesssteel, shape memory metals, ceramic composites, other composites, orother materials and may have any of a variety of cross sectional shapessuch as D-shape, B-shape, U-shape, round, half-round, oval, rectangular,or ribbon-like. In this embodiment of an atraumatic wire basket, forexample, two wire loops 120 a, 120 b may be used to form a basket withfour legs as shown in FIG. 11C, or three wire loops may be used to forma basket with six legs (not shown), and so on. Additional wire loops maybe used to form a basket with more than the four or six legs shown.Referring to FIG. 11C, the two end-sections 1, 1′ of each wire loop arebrought together at the basket base 20 and held in place by welding,soldering, ligating, gluing, crimping or any other means known in theart. The end-sections 1, 1′ of the wire loops can be affixed as shown inFIG. 11D to a cable, coil, shaft, mandril wire or guidewire 18 that runslongitudinally in a sheath 12 as shown in FIG. 1E and FIG. 1F. A channel200 may run through the sheath 12 and the proximal end 20 of the basket10 to accommodate a ram-rod, laser or other lithotriptic device 9 asshown in FIG. 1H and described earlier.

A basket of the invention having two or more wire loops 120 a, 120 beach with semi-circular protrusions 140 at the apex 130 of the loops 120a, 120 b, has enhanced basket stability and dilatative strength withoutsubstantially compromising basket flexibility. In this embodiment of theinvention (FIGS. 11C and 11D), the wires are unlikely to slide by oneanother at the distal tip. The semi-circular protrusions also help toreduce the stress on the basket legs while closing the basket.

The legs of an atraumatic wire basket 10 illustrated in FIGS. 11A-11Dand FIGS. 12A-12D may be gently curved or may have a plurality ofangular bends. In one embodiment, illustrated in FIG. 12A, each of thelegs 11 a, 11 b of a loop 120 a have five angular bends, 17 a, 17 a′, 17a″, 17 a″′, 17 a″″ forming at least two shoulders 15′ and 15″ on eachleg 11 a, 11 b of the wire loop 120. A three-dimensional basket shapeformed by two loops 120 a, 120 b of the type illustrated in FIG. 12A isshown in FIG. 12B. FIG. 12A illustrates a wire loop 120 configurationwhere all of the angles 17 of the loop are obtuse. A three-dimensionalbasket shape formed by two loops 120 a, 120 b of the type illustrated inFIG. 12A is shown in FIG. 12C. An infinite number of obtuse angles inboth legs of the wire loop results in a smoothly curved loop asillustrated in FIG. 12B. A largely oval or round, atraumaticthree-dimensional basket shape 10 formed by two basket loops 120 a, 120b of the type illustrated in FIG. 12B is shown in FIG. 12D. The legs 11a, 11 b, 11 c, 11 d of the baskets illustrated in FIGS. 11B, 11D, 12Cand 12D may be pre-formed, and their cross-section may be B-shaped,D-shaped, U-shaped, round, half-round, oval, rectangular, ribbon-like,or a variety of other cross-sectional shapes such as those shown inFIGS. 2D and 2E.

In yet another embodiment of an atraumatic wire basket illustrated inFIG. 13A, the distal ends 3 a, 3 b, 3 c, 3 d of the basket wires 3insert into a cap 160 with a core 170 at the basket tip 100 as shown inFIG. 13C. The distal ends 3 a, 3 b, 3 c, 3 d of the wires are affixed tothe cap 160 by soldering, gluing or any means known in the art. Thewires emerging from the cap are bent and then drawn down proximally asindicated by the arrows in FIG. 13B to form basket legs 11 a, 11 b, 11c, 11 d. The end-sections of the legs 1 a, 1 b, 1 c, 1 d are gatheredtogether at the basket base 20 to form an atraumatic wire basket 10 asshown in FIG. 13A. The end-sections 1 a, 1 b, 1 c, 1 d can be joined toa cable, shaft or coil (not shown).

In some embodiments of the invention, the sheath 12 of the medicalretrieval device is manufactured from polyimide, PTFE, composites orsimilar materials. In order to prevent the distal end 16 of a polyimidesheath 12 from splitting, a metal ring 180, as illustrated in FIG. 14,is inserted into the lumen 14 of the distal end 16 of a polyimide sheath12. The metal ring 180 is flush with the end 16 of the polyimide sheathor may protrude slightly beyond the end of the sheath as illustrated inFIG. 14.

In yet another aspect, the invention relates to a method for retrievingmaterial from a body such as a body tract or body canal. Material (e.g.,biological or foreign) can be retrieved from a body by using a tiplessbasket where at least a distal portion of the basket is defined by ashape which comprises a single unit or by using an atraumatic wire loopbasket, each basket wire forming a loop with a distal atraumaticprotrusion. The basket of the retrieval device has a tipless or anatraumatic distal end and thus allows the capture of material that islocated in pockets or other difficult-to-access areas within the body.Because the distal basket end is atraumatic, it can make intimatecontact with the surface of tissue, even the walls or lining of apocket-type area, and allows the retrieval of stones or other materialsthat are unrecoverable with conventional tipped baskets that can causetissue trauma and are limited, by the existence of the protruding tip,in how close the basket can approach the tissue. A method for retrievingmaterial from a body includes inserting a retrieval device with anatraumatic basket into the body, moving the tipless basket into theextended position, maneuvering the basket via one or more actuators onthe proximal handle (which is located outside of the body) of theretrieval device until the material (e.g., stone) is entrapped withinthe three-dimensional basket structure, and capturing the materialwithin the basket by moving the basket relative to the sheath to closethe basket legs around the material. With the material so gripped orheld by the basket, the basket can be withdrawn from the body to removethe material from the body. Before the basket is withdrawn from the bodywith the captured material, the material can be broken apart by, forexample, laser energy or lithotripsy. Mechanisms for breaking up thematerial before its removal from the body can be part of the retrievaldevice or can be separate tools/devices that are also inserted into thebody and utilized at the appropriate time in the stone removalprocedure. The material that can be captured with tipless basketsaccording to the invention includes a thrombus, embolus, foreign body,calculus, or a stone, such as a kidney stone, a ureteral stone, aurinary bladder stone, a gall bladder stone, a stone within the biliarytree, tumor, polyp or foreign body.

Variations, modifications, and other implementations of what isdescribed herein will occur to those of ordinary skill in the artwithout departing from the spirit and the scope of the invention asclaimed. Accordingly, the invention is to be defined not by thepreceding illustrative description but instead by the spirit and scopeof the following claims.

What is claimed is:
 1. A medical retrieval device, comprising: a sheathhaving a proximal end and a distal end; a handle at the proximal end ofthe sheath; and a basket for removing material from a body, the baskethaving a collapsed position where the basket is enclosed within thesheath, and an expanded position where the basket extends from thedistal end of the sheath, the basket comprising two or more pairs ofbasket legs, each pair of basket legs formed from a single wire loop,each wire loop comprising a protrusion at an apex of said wire loopwhere said wire loops intersect at a distal basket end, wherein saidprotrusions have a convex surface and a concave surface, said convexsurface of one basket wire protrusion being unsecured to said concavesurface of said intersecting basket wire protrusion.
 2. The basket ofclaim 1 further comprising a semi-circular protrusion.
 3. The basket ofclaim 1 wherein the basket legs are smoothly curved.
 4. The basket ofclaim 1 wherein the basket legs comprise a plurality of angles.
 5. Thebasket of claim 1 further comprising basket legs with cross-sectionalshapes selected from the group consisting of D-shape, U-shape, B-shape,rectangular, round, half-round, oval or ribbon-like.
 6. A method forretrieving material from a body, the method comprising the steps of:inserting a retrieval device into a body, the retrieval devicecomprising a sheath having a proximal end and a distal end, a handle atthe proximal end of the sheath, and a basket for removing material froma body, the basket having a collapsed position where the basket isenclosed within the sheath, and an expanded position where the basketextends from the distal end of the sheath, the basket comprising two ormore pairs of basket legs, each pair of basket legs formed from a singlewire loop, each wire loop comprising a protrusion at an apex of saidwire loop where said wire loops intersect at a distal basket end,wherein said protrusions have a convex surface and a concave surface,said convex surface of one basket wire being unsecured to said concavesurface of said intersecting wire protrusion; capturing the materialwithin the basket; and withdrawing the retrieval device from the body toremove the captured material from the body.